Spicer
®
Single Drive Axles
Service Manual
AXSM0055
April 2011
S110 Series
S130 Series
General Information
General Information
The description and specifications contained in this service
publication are current at the time of printing.
Dana reserves the right to discontinue or to modify its
models and/or procedures and to change specifications
at any time without notice.
Important Notice
This symbol is used throughout this
manual to call attention to procedures
where carelessness or failure to follow
specific instructions may result in
personal injury and/or component
damage.
Departure from the instructions, choice
of tools, materials and recommended
parts mentioned in this publication
may jeopardize the personal safety
of the service technician or vehicle
operator.
Any reference to brand name in this publication is made simply as an example of the types of tools and materials recommended for use and should not be considered an
endorsement. Equivalents, if available, may be used.
WARNING: Failure to follow indicated
procedures creates a high risk of personal
njury to the servicing technician.
i
CAUTION: Failure to follow indicated
procedures may cause component
damage or malfunction.
IMPORTANT: Highly recommended
procedures for proper service of this unit.
NOTE: Additional service information not
cover ed in the service procedures.
General Information
TIP: Helpful removal and installation
procedures to aid in the service of this unit.
Refer to the OEM vehicle specifications
OEM
Always use genuine Spicer replacement parts.
i
Table of Contents
General Information .............................................i
Important Notice.......................................................... i
Introduction ........................................................1
Model Listing.............................................................. 1
Model Information ...................................................... 1
Model Identification .................................................... 2
Part Identification........................................................ 2
Ring Gear and Pinion ..........................................3
Inspection ...........................................................4
Failure Analysis........................................................... 4
How to Diagnose a Failure........................................... 4
.........................Prepare the Parts for Inspection 5
Find the Cause of the Failure....................................... 5
Correct the Cause of the Problem............................... 5
Inspection................................................................... 6
Inspect Axle Housing .................................................. 6
Inspect Components................................................... 7
Inspect Primary Gearing ............................................. 7
Differential Carrier Assembly ..............................8
S110 Carrier Assembly .......................................9
S130 Carrier Assembly .....................................11
Remove Differential Carrier ...............................12
Standard Differentials................................................ 12
Install Differential Carrier ..................................13
Remove Wheel Differential ................................14
Pinion - Parts Exploded View ............................15
Pinion Removal .................................................16
Drive Pinion ......................................................17
Rear Axle Pinion Assembly - Parts Exploded View.... 17
Pinion Installation .............................................18
Final Buildup............................................................. 18
Wheel Differential Assembly - Parts Exploded ..20
Disassemble, Overhaul, and Assemble Wheel
Differential - S110 .............................................21
Disassemble Wheel Differential ................................. 21
Disassemble, Overhaul, and Assemble Wheel Differ-
ential - S130 .....................................................26
Disassemble Wheel Differential ................................. 26
Measure and Adjust Carrier Assembly ..............32
Adjust Backlash and Preload ..................................... 32
Change Backlash Setting........................................... 33
Measure Ring Gear Runout ....................................... 33
Adjust Ring and Pinion Tooth Contact Pattern ..34
Install Axle Housing Breather ............................36
Wheel End Seal - Parts Exploded View .............37
Remove and Overhaul Wheel End Seal .............38
Adjust Wheel Bearing ........................................39
Wheel End .........................................................41
Verify Wheel End-play Procedure .............................. 41
Adjust End-play with Tire and Wheel Assembly......... 41
Adjust End-play with Wheel Hub................................ 41
Readjust Wheel End-play Procedure.......................... 41
Lubricate Wheel End .........................................42
Lubrication ........................................................ 44
Approved Lubricants ................................................. 44
Recommendations for Viscosity/Ambient Temp........ 44
Lube Change Intervals............................................... 45
Change Lube .....................................................46
Drain .......................................................................... 46
Fill.............................................................................. 46
Proper Vehicle Towing ......................................47
With Truetrac Limited Slip Differential....................... 47
Torque Flow ......................................................48
Torque Chart .....................................................49
Introduction
Introduction
Dana Commercial Vehicle Division, presents this publication to aid in maintenance and overhaul of Spicer single drive axles.
Instructions contained cover the models listed. Their design is common, with differences in load capacity. Capacity variations
are achieved by combining basic differential carrier assemblies with different axle housings, axle shafts and wheel equipment.
Model Listing
Rear Axle Load Capacity
S10-110 10,000
S12-110 12,000
S14-110 14,000
S16-130 16,000
Model Information
S - S i ngle Rear A xle
G A W Rating x 1 0 0 0 lbs.
Gear Typ e
1 - S tan dard S i n gle Redu ct io n
2 - Dual R a n g e
3 - P lanet ary Dou b le Redu ctio n
4 - Con trolled T r action Diff erent ial
5 - H elical R e d uct i on
Introduction
S 14 - 1 1 0 L
O p t i o n s
B - B u s Specif i c
D - D iff erent ial L ock
H - H eavy Wall
I - I n t e g ral B rake
L - Limit e d-Slip
R - R e t ard e r/Par king Brake Read y
W - Wid e - t r ack
F - Roll Over
D esign L evel
H ead A ssem bly S e r ies
1
Model Identification
Drive Axle
Data plate is located on
the axle centerline
Introduction
3
2
4
CUST. PART NO.
SPEC. SERIAL NO.
MODEL PART NO. RATIO
MADE IN:
Spicer
5
®
6
Rear Axle (Front View)
1 - Country of origin
2 - Axle model identification
3 - Specification number assigned to the axle built by Spicer.
Identifies all component parts of the axle including special
special OEM requirements such as yokes or flanges.
4 - OEM part number assigned to the axle build
5 - Carrier assembly serial number assigned by the
manufacturing plant
6 - Axle gear ratio
7 - Carrier assembly production or service part number
Part Identification
Axle Housing Axle Shaft
®
LBS.
Spicer
PT. NO.
HSG. CAP.
. I.D. NO.
ADE IN
HSG
HOUSING M
1
1
7
2
1 - ID Tag 2 - Axle shaft part number
2
Introduction
Ring Gear and Pinion
Note: Ring gear and drive pinion are matched parts and must be replaced in sets.
127381
1
3
L7038
G
17
OF
4
6
SPICER
7
8
41-8
NL2
5
2
8
8-41
127428
127
6
0H
17
G
Introduction
127
7
SPICER
3
1
1 - Part number
2 - Number of ring gear teeth
3 - Manufacturing numbers
6-39
JD77
85405
8
6
4
4 - Matching gear set number
5 - Number of pinion teeth
7 - Indicates genuine Spicer parts
8 - Heat Code
6 - Date code
3
Inspection
General Information
Failure Analysis
Failure analysis is the process of determining the original
cause of a component failure in order to keep it from happening again. Too often, when a failed component is
without determining its cause, there will be a recurring failure.
If a carrier housing is opened, revealing a ring gear with a broken tooth, it is not enough to settle on the broken tooth as the
cause of the carrier failure.
examined. For a thorough understanding of the failure and
possible insight into related problems, the technician needs to
observe the overall condition of the vehicle.
No one benefits when a failed component goes on the junk
pile with th
customer than a repeat failure. Systematically analyzing a failure to prevent a repeat occurrence assures quality
avoiding unnecessary downtime and further expense to the
customer.
The true cause of a failure can be better determined by knowing what to look for, determining how a piece of the equipment was running and learning about previous problems. In
the
been installed. The more successful shops prevent repeat
equipment failures by developing good failure analysis practices. Knowing how to diagnose the cause of a premature failure is one of the prerequisites of
technician.
e cause unknown. Nothing is more disturbing to a
case of a rebuilt rear axle, mismatched gears may have
Other parts of the carrier must be
a good heavy-equipment
replaced
service by
How to Diagnose a Failure
The following five steps are an effective approach to good failure diagnostics.
1. Document the problem.
2. Make a preliminary investigation.
3. Prepare the parts for inspection.
4. Find the cause of the failure.
5. Correct the cause of the problem.
4. Ask: In what type of service is the truck being used?
5. Ask: Has this particular failure
6. Ask: How was the truck working
You need to be a good listener. Sometimes, insignificant or unrelated symptoms can point to the cause of the failure:
7. Ask: Was the vehicle operating at normal temperatures?
8. Ask: Were the gauges showing normal ranges of
operation?
9. Ask: Was there any unusual noise or vibration?
After listening, review the previous repair and maintenance
rds. If there is more than one driver, talk to all of them
reco
and compare their observations for consistency with the service and maintenance records. Verify the chassis Vehicle
entification Number (VIN) number from the vehicle identifi-
Id
cation plate, as well as the mileage and hours on the vehicle.
Make a Preliminary Investigation
These steps consist of external inspections and
that will be valuable when combined with the results of the
parts examination.
1. Look for leaks, cracks or other damage that can
point to the
2. Make note of obvious lea
A missing fill or drain plug would be an obvious
cause for concern.
3. Look for cracks in the carrier housing (harder to see,
but s
4. Does the general mechanical condition of the vehicle
ind
icate proper maintenance or are there signs of
neglect?
5. Are the tires in good condition and do
match?
6. If equipped with a torque-limiting device, is it working properly?
cause of the failure.
ometimes visible).
occurred before?
prior to the failure?
observations
ks around plugs and seals.
the sizes
Document the Problem
Here are some guidelines for starting to learn
including questions to ask:
1. Talk to the operator of the truck.
2. Look at the service records.
3. Find out when the truck was last serviced.
4
about a failure,
During the preliminary investigation, w
of the ordinary for later reference. Items that appear insignificant now may take on more importance when the subassemblies are torn down.
rite down anything out
Prepare the Parts for Inspection
Inspection
After the preliminary investigation, locate the failure and prepare the part for examination. In carrier
be necessary to disassemble the unit.
1. When disassembling subassemblies and parts, do
not clean the parts
destroy some of the evidence.
2. When tearing down the drive axle, do it
mended manner. Minimize any further damage to the
.
unit
3. Ask more questions when examining the interior
the carrier . Does the lubricant meet the manufacturer
specifications regarding quality, quantity and viscosity? As soon as you have located the failed part, take
to analyze the data.
time
immediately since cleaning may
failure analysis, it may
in the recom-
Find the Cause of the Failure
Here begins the real challenge to determine the exact cause of
the failure. Keep in mind that there is no benefit to replacing a
failed part without determining the cause of the failure. For
example, after examining a failed part and finding that the failure is caused by a lack of lubricati
there was an external leak. Obviously, if there is an external
leak, just replacing the failed gear is not going to correct the
situation.
of
Another important consideration is
type of failure which can be a valuable indicator for the cause
of failure. The following pages show different types of failures
and possible causes. Use this as a guide in determining types
of failures and in correcting problems.
on, you must determine if
to determine the specific
Correct the Cause of the Problem
Once the cause of the problem has been determined, refer to
the appropriate service manual to perform the repairs.
Inspection
5
Inspection
Inspection
Clean
1. Wash steel parts with ground or polished surfaces in
solvent. There
vents available. Kerosene and diesel fuel are acceptable.
Gasoline is not an acceptable solvent because of its
eme combustibility. It is unsafe in the workshop envi-
extr
ronment.
2. Wash castings or other rough parts in solvent or
clean in hot solution tanks
tions.
Note: If a
hot solution tank is used, make sure parts are
heated thoroughly before rinsing.
3. Rinse thoroughly to remove all traces of the cleaning
ion.
solut
4. Dry parts immediately with clean rags.
5. Oil parts.
• If parts are to be reused immediately: Lightly oil.
• If parts are to be stored: Coat
sion resistant paper and store in a clean, dry place.
are many suitable commercial sol-
WARNING
using mild alkali solu-
with oil, wrap in corro-
Inspect Axle Housing
Axle housing inspection and repairs are limited to the following checks or repairs.
• Visually inspect axle housing for cracks, nicks and
burrs
on machined surfaces.
• Check carrier bolt holes and studs for foreign material.
• Replace damaged fasteners. Look
cross-threaded holes
CAUTION
Any damage which affects the alignment or structural integrity of the housing requires housing replacement. Do not
pair by bending or straightening. This process can affect
re
the material’s properties and cause it to fail completely
under load.
• Check all seals and gaskets.
Note: Replace
ket compound (included in many repair kits). The compound provides a more effective seal against lube
seepage and
when replacing parts.
conventional gaskets with silicone rubber gas-
is easier to remove from mating surfaces
for loose bolts or
1
2
1 - Axle housing
2 - Machined surface
6
Inspect Components
Inspect all steel parts for:
• Notches, visible steps or grooves created by wear.
• Pitting or cracking along gear contact lines.
• Scuffing, deformation or discolorations. These are
signs of
related to low lubrication levels or improper lubrication practices.
In addition, inspect the following for damage:
• Differential gearing
• Bearings for loose fit on drive pinion, and differential
bearin
• All fasteners for rounded heads, bends, cracks or
dam
excessive heat in the axle and are usually
gs.
aged threads.
Inspection
• Inspect machined surfaces of cast or malleable
parts. They
scoring, and wear .
• Look for elongation of drilled holes, wear on surfaces machined for bearing fits and nicks or burrs in
mating sur
must be free of nicks, burrs, cracks,
faces.
Inspect Primary Gearing
Before reusing a primary gear set, inspect teeth for signs of
excessive wear. Check tooth contact pattern for evidence of
incorrect adjustment.
Inspection
7
Differential Carrier Assembly
Differential Carrier Assembly
1 - Carrier fastener
2 - Carrier assembly
1
2
8
S110 Carrier Assembly
Carrier Assembly
30
29
28
27
21
25
24
26
20
17
19
22
16
18
31
23
12
13
10D
11
10C
10B
10, 10A
(10A includes items 10B, 10C and 10D)
9
8
7
6
5
4
15
14
3
Carrier Assembly
32
(Optional Truetrac)
2
1
9
Carrier Assembly
1 - Pinion Nut
2 - End Yoke
3 - Slinger
4 - Outer Pinion Bearing Cone
5 - Outer Pinion Bearing Cup
6 - Pinion Spacer
7 - Inner Pinion Bearing Cup
8 - Inner Pinion Bearing Cone
9 - Drive Pinion
10 - Carrier Housing
10A - Carrier Housing Assembly
10B - Switch
10C - Capscrew
10D - Backing Ring
11 - Ring Gear
12 - Ring Gear Bolt
13 - Ring Gear Bearing Cone
14 - Ring Gear Bearing Cup
15 - Ring Gear Bearing Adjuster
16 - Side Pinion Thrust Washer
17 - Side Pinion
18 - Side Gear
19 - Differential Shaft
20 - Pin
21 - Capscrew
22 - Flat Washer
23 - Flanged Half Cap
24 - Plain Half Cap
25 - Cotter Pin
26 - Side Gear Thrust Washer
27 - Differential Case
28 - Differential Case Bearing Cone
29 - Differential Bearing Cup
30 - Differential Case Bearing Adjuster
31 - Pipe Plug
32 - Optional Truetrac
10
S130 Carrier Assembly
Carrier Assembly
31
30
29
28
19
20B
27
20A
22
17
26
25
18
21
23
32
24
9
15
14
10D (Optional)
11
12
10B (Optional)
10C (Optional)
10, 10A (Optional)
(10A includes items 10B, 10C and 10D)
8
7
6
5
4
3
13
16
Carrier Assembly
1 - Pinion Nut
2 - End Yoke
3 - Slinger
4 - Outer Pinion Bearing Cone
5 - Outer Pinion Bearing Cup
6 - Pinion Spacer
7 - Inner Pinion Bearing Cup
8 - Inner Pinion Bearing Cone
9 - Drive Pinion
10 - Carrier Housing
10A - Carrier Housing Assembly
10B - Switch
10C - Capscrew
10D - Backing Ring
11 - Diff Case Dowels
12 - Ring Gear
13 - Ring Gear Bolt
14 - Flange Half Bearing Cone
15 - Flange Half Bearing Cup
2
1
16 - Fland Half Bearing Adjuster
17 - Side Pinion Thrust Washer
18 - Side Pinion
19 - Side Gear
20A - Differential Shaft
20B - Differential Stub Shaft
21 - Pin
22 - Capscrew
23 - Flat Washer
24 - Flange Half Cap
25 - Plain Half Cap
26 - Cotter Pin
27 - Side Gear Thrust Washer
28 - Plain Half Diff Case
29 - Plain Half Bearing Cone
30 - Plain Half Bearing Cup
31 - Plain Half Bearing Adjuster
32 - Pipe Plug
33 - Optional Truetrac
11
Differential Carrier Assembly
Remove Differential Carrier
Standard Differentials
1. Block the vehicle.
2. Drain axle lubricant. Remove bottom two (2) capscrews.
3. Disconnect driveline.
4. Remove axle shafts. (If used, remove lock washers
and tap
er dowels.)
WARNING
WARNING
Do not lie under carrier after fasteners are removed. Use
ission jack to support differential carrier assembly
transm
prior to loosening fasteners.
CAUTION
CAUTION
Do not strike the shaft head with a steel hammer. Do not
sels or wedges to loosen shaft or dowels.
use chi
5. Remove carrier capscrews and washers.
6. Remove differential carrier assembly.
12
Differential Carrier Assembly
y
Install Differential Carrier
IMPORTANTIMPORTANT
Before installing carrier assembly, inspect and thoroughly
clean interior of axle housing using an appropriate solvent
and clean rag.
1. Apply Spicer approved RTV compound on axle
housing mating surface as shown in the illustration.
Completely remove all old gasket material prior to
applying new material. Compound will set in 20 minutes. Install carrier before compound sets or reapply.
1
1 - Apply RTV gasket in this pattern
TIP: To assist in installing complete differential carrier use
two pieces of threaded rod (M14 X 2) threaded into carrier
capscrew holes. Rod should be approximately 4" (102 mm)
long. Use these to pilot the carrier into the housing.
2. Install carrier to housing, lock washers and capscrews. Torque to proper specification. Torque to
142–158 lbs. ft. (193–214 N•m).
3. Install axle shafts and axle stud nuts.
Add axle lubricant. Fill to bottom of filler hole in car-
4.
.
rier
5. Connect main driveline and lubricate joints.
Differential Carrier
Assembl
13
Remove Wheel Differential
Differential Carrier Assembly
Note: Omit this step if the gear set is to be replaced. If gear
set is to be reused, check tooth contact pattern and ring
gear backlash before disassembling differential carrier.
When checking backlash, a yoke must be installed and
torqued to get an accurate reading. Best results are
obtained when established wear patterns are maintained
in used gearing.
1. Mount differential carrier in repair stand.
Note: For easier disassembly
ion (self-locking) nut.
, loosen but do not remove pin-
3. Remove capscrews and bearing ca
ing adjusters and remove adjusters and
cups.
4. Lift ring gear and differential
assembly out of carrier.
ps. Back off bear-
bearing
2. Punch mark bearing caps. If reusing
punch mark bearing adjusters for reference during
assembly.
1
1 - Punch Marks
gear set, also
14
y
Pinion - Parts Exploded View
11
Differential Carrier Assembly
10
1 - Pinion Nut
2 - End Yoke
3 - Slinger
4 - Oil Seal
5 - Outer Pinion Bearing Cone
6 - Outer Pinion Bearing Cup
9
8
7
6
5
4
3
2
1
7 - Pinion Spacer
8 - Inner Pinion Bearing Cup
9 - Inner Pinion Bearing
10 - Drive Pinion
11 - Carrier
Differential Carrier
Assembl
15
Pinion Removal
Differential Carrier Assembly
1. Remove yoke nut.
2. Remove yoke using a yoke puller service tool.
1
1 - Yoke puller
3. Remove oil seal.
4. Place carrier in a press with
threaded end of pinion
face up.
6. Press pinion through outer bearing and out
of carrier
casting.
7. Remove bearing preload spacer and save for use in
reassembly
.
8. Remove inner bearing cone from pinion using a
split-type puller
. Use two procedure steps to remove
each bearing.
a. Mount puller vertically to separate the bearing. This
action will for
ce puller halves under bearing and start
moving bearing off pinion.
5. Place a wood block under pinion to avoid damage to
gear teeth.
1
2
3
6
5
4
1 - Press
2 - Outer bearing
3 - Inner bearing
4 - Wood block
5 - Drive pinion
6 - Bearing preload spacer
b. Mount puller horizontally to press pinion out of bear-
ing.
1
1 - Press
9. If bearings are to be replaced, remove bearing cups
carrier casting at this time. Pinion removal
from
complete.
16
Drive Pinion
Drive Pinion
Rear Axle Pinion Assembly - Parts Exploded Vi
10
9
8
7
6
5
4
Drive Pinion
ew
1 - Pinion Nut
2 - End Yoke
3 - Slinger
4 - Oil Seal
5 - Outer Pinion Bearing Cone
3
2
1
6 - Outer Pinion Bearing Cup
7 - Pinion Spacer
8 - Inner Pinion Bearing Cup
9 - Inner Pinion Bearing Cone
10 - Drive Pinion
17
Pinion Installation
Drive Pinion
Final Buildup
Note: Do not install oil seal in carrier until bearing preload is
correctly adjusted.
1. Press inner bearing cone on pinion.
3. Press inner and outer bearing cups into
until seated. Use a feeler gage (.0015" [.038 mm]
approx.) to make sure that bearing cups are fully
seated in bearing bores. Apply lubricant to both cup
and cone.
4. Place carrier housing in press with the pinion sup-
ported by wood block (6" x 6" x 6" [152 x 152 x 152
m]), so the inner pinion bearing is mated to the
m
cone.
1
2
3
the carrier
5
4
IMPORTANTIMPORTANT
To prevent bearing damage, use suitable sleeve that only
acts inner race of bearing cone.
cont
2. Install preselected bearing spacer.
1 - Press
2 - Outer pinion bearing
3 - Wood block
4 - Drive pinion
5 - Bearing preload spacer
5. Press outer bearing onto pinion until completely
seated. Rotate carrier during
6. Use torque multiplier and torque pinion nut to
62
5-753 lbs. ft. (847-1021 N•m).
seating process.
18
Drive Pinion
7. Measure torque to rotate the pinion with an inchpound torque wrench. Torque measurements should
be taken every fourth (4th) revolution and should
read between 20-40 in. lbs. (2.3-4.5 N•m) of bearing
preload.
Note: If bearing preload does not fall within allowed limits,
preload can be increased by using a thinner spacer and
decreased by using a thicker spacer.
Pinion bearing preload spacers are available in the
following thicknesses 27.44-28.00 mm.
Always measure each spacer before assembly to
ensure correct thickness.
8. Repeat process until torque to rotate is between
20-40 in. lbs. (2.3-4.5 N•m). After proper preload is
achieved, remove yoke and install new seal with
proper service tool.
10. Handle the seal by its outside diameter avoiding any
contact with the seal lips. During installation, use the
proper driver to make sure that the seal is mounted
properly.
11. Use a rubber mallet to drive the seal tool in until the
flange bottoms on the housing cover bore face. The
flange will locate the seal at the proper depth.
1
2
3
12. Install end yoke.
Note: Spicer recommends that new torque prevailing
nuts be used.
13. Use torque multiplier and torque pinion nut to
625-753 lbs. ft. (847-1021 N•m).
1 - Seal Driver
2 - Oil Seal
3 - Pinion Cage
Drive Pinion
CAUTIONCAUTION
Do not use any silicone or permatex-type bore sealant with
this seal.
9. Remove the new seal from its package and install
with the proper driver:
R-Pinion-Use drive #126917 only
WARNINGWARNING
Due to the resiliency of the plasti
y occur when the seal is seated. Keep clear of the ham-
ma
c driver, hammer rebound
mer rebound path!
19
Wheel Differential Assembly
Wheel Differential Assembly - Parts Exploded
9
8
10
8
6
7
7
9
6
S130
8
10
7
5
8
9
15
14
9
13
12
16
11
9
8
7
10
3
2
1
4
6
S110
1 - Diff. Case Bearing Adjuster
2 - Diff. Bearing Cup
3 - Diff. Case Bearing Cone
4 - Differential Case
5 - Side Gear Thrust Washer
6 - Side Gear
7 - Differential Shaft
8 - Side Pinion
20
6
8
5
9
9 - Side Pinion Thrust Washer
10 - Pin
11 - Ring Gear
12 - Ring Gear Bolt
13 - Ring Gear Bearing Cone
14 - Ring Gear Bearing Cup
15 - Ring Gear Bearing Adjuster
16 - Locating Dowels
Wheel Differential Assembly
y
Disassemble, Overhaul, and Assemble Wheel Differential - S110
Disassemble Wheel Differential
1. Remove capscrews fastening ring gear to differential
case.
2. The ring gear to differential case interface is a press
fit. Place the assembly
ing downward. Support the assembly on either side
ring gear. Thread a capscrew back into one of
of the
the case holes by hand. Press down on the head of
the capscrew, you may need to press in more than
one position to free the ring gear from the case.
in a press with the case fac-
CAUTIONCAUTION
The differential case and gears will fall after separation.
rt the case so that it will not cause damage to the dif-
Suppo
ferential or bodily injury.
3. Lift out outer side gear.
4. Remove differential shaft locking pin with pliers.
1
Wheel Differential
Assembl
1 - Locking pin
washers.
IMPORTANTIMPORTANT
Do not press on the wheel differential shaft to free the ring
r from the case. Pressing on the wheel differential shaft
gea
may cause it to bend and/or fatigue.
5. Remove shaft, side pinions and thrust
21
Wheel Differential Assembly
6. Remove inner side gear and thrust washer.
7. Remove bearing cones from ring gear and differential case in two steps:
a. Mount puller vertically to sp
will start moving bearing off case and gear .
lit bearing. This action
b. Mount puller horizontally to remove cone.
8. Press new bearing cone on differential case.
22
9. Place thrust washer on side gear. Lubricate both
sides of the
thrust washer. Install on side gear.
Wheel Differential Assembly
y
10. Install inner side gear and thrust washer in differential case.
11. Start wheel differential shaft in differential
the locking pin hole facing up.
case with
14. Make certain the hole in the shaft and case line up
and install the
15. Install outer side gear.
Note: No
thrust washer is used at this location.
locking pin.
Wheel Differential
Assembl
12. Install the first side pinion thrust washer and gear.
Push shaft through washer an
13. Install second side pinion and thrust washer. Push
through washer and side pinion until it is flush
shaft
to the outside of the case.
d side pinion.
1
16. Lower ring gear onto case assembly aligning the ring
gear caps
crew holes.
23
Wheel Differential Assembly
17. Install and hand-tighten all new ring gear capscrews.
18. The interface of the ring gear to differential case is a
s fit. Put the assembly in a press with the ring
pres
gear facing upward. Make certain that the ring gear
is flush and square to the differential case before
pressing. Press until ring gear bottoms out on the
case.
IMPORTANTIMPORTANT
DO NOT use the capscrews to draw the ring gear into place.
Only use a press.
19. Press new ring gear bearing cone.
IMPORTANTIMPORTANT
When pressing differential case bearing cones, note that
e bearing is beyond flush with the top of the case. The
th
cone must be fully seated. To prevent bearing damage, use
suitable sleeve that only contacts the inner race of the
cone. A used bearing race would be a suitable tool. This
tool should have a slit cut if the ID is the same as the bearing boss OD.
24
20. Tighten and torque ring gear c
nating pattern. 140-160 lbs. ft. (190-217 N•m).
apscrews in an alter-
Wheel Differential Assembly
y
21. Install differential case assembly into carrier. Be
careful not to damage the differential bearings lower
ing the assembly.
22. Lubricate the differential bearings and install bearing
cups and
differential bearing adjusters.
-
Wheel Differential
Assembl
25
Wheel Differential Assembly
Disassemble, Overhaul, and Assemble Wheel Differential - S130
Disassemble Wheel Differential
1. Remove capscrews fastening ring gear to differential
case.
2. The ring gear to differential case interface is a press
fit. Place the assembly
ing downward. Support the assembly on eitiher side
ring gear. Thread a capscrew back into one of
of the
the case holes by hand. Press down on the head of
the capscrew, you may need to press in more than
one position to free the ring gear from the case.
in a press with the case fac-
CAUTIONCAUTION
The differential case and gears will fall after separation.
Suppo
rt the case so that it will not cause damage to the dif-
ferential or bodily injury.
3. Remove the outer side gear.
4. Remove the differential shaft locking pins by turning
the differe
hammer to lightly tap on the side of the case to free
the locking pins.
ntial case opening facing down. Use a
IMPORTANTIMPORTANT
Do not press on the wheel differential shaft to free the ring
r from the case. Pressing on the wheel differential shaft
gea
may cause it to bend and/or fatigue.
26
5. The locking pins are slip fit and should fall from the
case easily
.
Wheel Differential Assembly
y
6. Remove the half shafts first and then remove their
side pinions and thrust washers.
Half
Differential
Shaft
7. Remove the full shaft, side pinions and thrust washers.
9. Remove bearing cones from ring
gear and differential case in two steps:
A. Mount puller vertically to split bearing. This action
will start moving the bearing off case and gear.
B. Mount puller horizontally to remove cone.
Wheel Differential
Assembl
8. Remove inner side gear and thrust washer.
10. Press new bearing cone on the differential case.
27
Wheel Differential Assembly
11. Place thrust washer on the side gear. Lubricate both
sides of the thrust washer before installing.
12. Install the side gear and thrust washer in the differential case.
15. Install the side pinion and thrust washer to the other
side of the
full shaft.
16. Install a side pinion and thrust washer on the half
shaft side.
Side Pinion
and Thrust
Washer
13. Start the full differential shaf
t into the shaft bores in
the case that does not have a locking pin hole.
Side Pinion
and Thrust
Washer
Full
Differential
Shaft
Locking
Pin Holes
14. Install a side pinion and thrust washer
shaft through the side pinion.
Side Pinion
and Thrust
Washer
and push the
17. Install the half shaft so that the pin is facing
and push it in until it stops.
Half
Differential
Shaft
Pin Hole
Facing
Upward
upward
28
Wheel Differential Assembly
y
18. The end of the half shaft should fit into the slot of
the full shaft at the same time as the hole in the case
lines up with the hole in the half shaft.
Align Pin
Holes
Fit End
Into Slot
19. Install the locking pins to both sides of the differential case.
Locking
Pin
21. Next, the two locating dowel pins that are pressed
into the ring
The dowel can only be pressed in one direction. Press
Note:
gear must be removed.
the dowels towards the inside of the gear.
22. Press the dowel pins into the holes that the shaft
locking
pins were installed.
Wheel Differential
Assembl
20. Install outer side gear .
Note: No thrust washer
is used at this location.
23. Lower the ring gear onto the case assembly aligning
the locking
dowels.
29
Wheel Differential Assembly
24. Install and hand-tighten all new ring gear capscrews.
25. The interface of the ring gear to differential case is a
pres
s fit. Put the assembly in a press with the ring
gear facing upward. Make certain that the ring gear
is flush and square to the differential case before
pressing. Press until ring gear bottoms out on the
case.
IMPORTANTIMPORTANT
DO NOT use the capscrews to draw the ring gear into place.
Only use a press.
26. Press new ring gear bearing cone.
IMPORTANTIMPORTANT
When pressing differential case bearing cones, note that
e bearing is beyond flush with the top of the case. The
th
cone must be fully seated. To prevent bearing damage, use
suitable sleeve that only contacts the inner race of the
cone. A used bearing race would be a suitable tool. This
tool should have a slit cut if the ID is the same as the bearing boss OD.
30
27. Tighten and torque ring gear c
nating pattern. See the "Torque Chart" on page 50
for torque specifications.
apscrews in an alter-
Wheel Differential Assembly
y
28. Install differential case assembly into carrier. Be
careful not to damage the differential bearings lower
ing the assembly.
29. Lubricate the differential bearings and install bearing
cups and
differential bearing adjusters.
-
Wheel Differential
Assembl
31
Wheel Differential Assembly
Measure and Adjust Carrier Assembly
Adjust Backlash and Preload
1. Turn the flange half-bearing adjuster in until the ring
gear contacts the pinion (zero backlash) then back
the adjuster out two (2) notches from the adjuster
lugs.
1
1 - Flange half
2 - Plain half
2. Tighten the plain half-adjuster until the bearing cup
just starts to turn, this is
a zero bearing preload.
4. Use a rubber mallet to make certain that both bearing adjusters are fully seated.
5. Measure backlash. Make sure it is within specification of .006"–.018” (.15-.46 mm).
o give yourself room to adjust contact pattern, set it
TIP: T
between .012"–.014” (.30-.36 mm).
2
3. Tighten the plain half-adjuster two lug notches. Start
the notch at the top, count two notches coun-
with
terclockwise on the adjuster, turn the adjuster so
that the
two-notch preload.
1 - Lugs
2 - One notch
32
notch is facing straight up. You now have a
2
1
Wheel Differential Assembly
y
Change Backlash Setting
If you have too much backlash, the ring gear needs to move
closer to the pinion. Back off the plain half-adjuster, counting
the number of notches you back it off (each notch equals
about .003" [.08 mm] of backlash).
IMPORTANTIMPORTANT
In order to maintain the differential bearing preload, you
l need to turn the flange half-bearing adjuster the same
wil
amount in the same direction. If you need more backlash,
reverse this procedure.
1. Install carrier bearing caps and torque
bolts to 130–150 lbs. ft. (176-203 N•m).
2. Recheck backlash: If the bearing
in straight or fully seated, the backlash will change.
a. Used Gearing
before disassembly.
b. New Ge
.006” and .018" (.15-.46 mm).
: Reset to backlash recorded
aring: Backlash should be between
carrier cap
adjusters were not
Measure Ring Gear Runout
Measure Ring Gear Total
1. Measure ring gear total radial runout. (Indicator
read
ing should not exceed .010" [.25 mm]).
2. Measure ring gear total backface runout.
reading should not exceed .010" [.25 mm]).
Wheel Differential
Assembl
(Indicator
3. Check ring gear tooth contact pattern.
teeth and check tooth contact pattern. Correct tooth
patterns, see "Adjust Tooth Contact Pattern."
4. Install bearing adjuster cotter pins.
Paint ring gear
33
Adjust Tooth Contact Pattern
Adjust Ring and Pinion Tooth Contact Pattern
Used Gearing - Correct Pattern
2
1
1 - Face width
2 - Tooth depth
3 - Heel
4 - Top land
5 - Root
6 - Toe
1. Identify if new or used gearing.
2. Check tooth contact pattern (new
New Gearing - Correct Pattern
• Paint six ring gear teeth 180° apart
to obtain a contact pattern. The correct pattern is
slightly below center on the ring gear tooth with
lengthwise contact up off the toe. The length of the
pattern in an unloaded condition is approximately
one-half (1/2) to two-thirds
(2/3) of the ring gear tooth in most models and
ios.
rat
• The pattern could vary in length and should cover
half (1/2)
tern should be evenly centered between tooth top
land and
of the tooth or more (face width). The pat-
root and should be up off the tooth toe.
or used gearing).
and roll the gear
• Used gearing will not usually display the square,
even contact pattern found in new gear
gear will normally have a “pocket” at the heal end of
the gear tooth. The more use a gear has had, the
more the line becomes the dominant characteristic
3
4
5
6
Adjust Contact Pattern
Note: This is a shimless pinion designed carrier
of the pattern.
• Adjust used gear sets to display the same contact
pattern
tern is up off the toe and centers evenly along the
face width
the length and shape of the pattern are highly variable and is considered acceptable as long as it does
no
1 - Pattern along the face width could be longer
• If necessary, adjust the contact pattern by changing
the ring
• Ring gear position controls the backlash. This
adjus
width of the gear tooth.
shows an incorrect pinion cone position, check to make
sure the inner pinion cup is fully seated. Use a feeler
gauge.
observed before disassembly. A correct pat-
between the top land and root. Otherwise,
t run off the tooth at any point.
gear position.
tment moves the contact pattern along the face
sets. The
. If the pattern
34
Adjust Tooth Contact Pattern
Adjust Ring Gear Position (Backlash)
If the ring gear pattern shows incorrect face width contact,
change backlash by
If the pattern is too close to the edge of the tooth toe, move the
gear away from the pinion to increase backlash.
ring
1. Loosen the bearing adjuster on the teeth side of the
ring
adjusting the ring gear.
gear several notches.
2. Loosen the opposite adjuster one notch.
3. Return to adjuster on teeth
tighten adjuster until it contacts the bearing cup.
4. Continue tightening the same adjuster two (2) or
three (3) notches
If the pattern is concentrated at the heel (too far up the tooth),
the ring gear toward the pinion to decrease backlash.
move
5. Loosen the bearing adjuster on the teeth side of the
gear several notches.
ring
6. Tighten the opposite adjuster one notch.
7. Return to adjuster on teeth side of ring gear and
tighten adjuster until it contacts the bearing cup.
and recheck backlash.
side of the ring gear and
Adjust Tooth Contact
Pattern
8. Continue tightening the same adjuster two (2) or
three (3) notches
and recheck backlash.
35
Install Axle Housing Breather
1. Install fitting in breather hole.
2. Tighten fitting finger tight.
Housing Breather
4. Insert hose onto fitting, long end down.
3. Torque to 5 lbs. ft. (7 N•m) and align the nose of the
brea
ther to the rear.
5. Push hose firmly against fitting. Rotate hose to point
wn.
do
36
Wheel End Seal
Wheel End Seal - Parts Exploded View
Wheel End Seal
1
2
1 - Installation tool
2 - Seal
3 - Rear hub
3
37
Remove and Overhaul Wheel End Seal
Wheel End Seal
WARNINGWARNING
Never work under a vehicle supported by only a jack.
Al
ways support vehicle with stands. Block the wheels and
make sure the vehicle will not roll before releasing the
brakes.
IMPORTANTIMPORTANT
Wheel end seals can be easily damaged during handling.
ve the seal in its package until installation to prevent
Lea
damage or contamination.
1. Remove outer nut and locking washer.
2. Remove inner nut.
3. Remove outer bearing and wheel.
4. Remove oil seal.
5. Remove inner bearing.
6. Inspect spindle journal and hu
burrs. Recondition with an emery cloth as required.
b bore for scratches or
Install Wheel End Seal
1. Before installation, lubricate the following with the
same
lubricant used in the axle sump.
• Inner bearing.
• Wheel seal (follow the directio
the seal supplier).
2. Place seal on installation tool.
3. Drive seal with installation tool onto hub.
ns provided by
Note: Deep
Always use the seal installation tool specified by the seal
nufacturer. Using an improper tool can distort or dam-
ma
age the seal and cause premature seal failure.
gouges can be repaired by filling gouge with hard-
ening gasket cement and smoot
7. Clean hub cavity and bearing
bly. Be sure to remove contaminants from all
recesses and corners.
8. Clean bearings thoroughly with solvent and examine
for damage. Replace
IMPORTANTIMPORTANT
hing with emery cloth.
bores before reassem-
damaged or worn bearings.
38
y
Adjust Wheel Bearing
Wheel Adjustment Systems
WARNINGWARNING
Do not mix spindle nuts and lock washers from different
systems. Mixing
wheel separation.
Note: The lock
nut system is thinner than the lock washer for a threepiece tang-type wheel nut system and is not designed to
bear against the inner nut.
1. Inspect the spindle and nut threads for
and clean thoroughly or replace as required.
Note: Proper assembly and
spindle or nut threads are corroded.
2. Inspect the tang-type washer (if used).
washer if the tangs are broken, cracked, or damaged.
3. Install the hub and drum on the spindle with care to
prev
spindle nuts and lock washers can cause
washer for a four-piece tang/dowel-type wheel
corrosion
adjustment is not possible if the
Replace the
ent damage or distortion to the wheel seal.
CAUTIONCAUTION
Never use an impact wrench to adjust wheel bearings. A
to
rque wrench is required to assure the nuts are properly
tightened.
8. Back off the inner nut one full turn. Rotate the wheel
b.
hu
9. Retighten the inner nut to 50 lbs. ft. (68 N•m) while
ro
tating the wheel hub.
10. Back off the inner nut exactly 1/4 turn.
Note: This adjustment
freely with 0.001" -.005” (0.025 mm–0.127 mm) end-
.
play
11. Install the correct lock washer for the wheel nut sys-
tem being used.
Three-piece Dowel-type Lock Washer System
procedure allows the wheel to rotate
Wheel Adjustment
S
stems
CAUTIONCAUTION
A wheel dolly is recommended during installation to make
at the wheel seal is not damaged by the weight of the
sure th
hub and drum. Never support the hub on the spindle with
just the inner bearing and seal. This can damage the seal
and cause premature failure.
4. Completely fill the hub cavity between the inner and
outer bearing races with the same lubricant
the axle sump.
5. Before installation, lubricate the outer bearing with
same lubricant used in the axle sump.
the
Note: Lubricate only with clean axle
type used in the axle sump. Do not pack the bearings
with grease before installation. Grease will prevent the
proper circulation of axle lubricant and may cause wheel
seal failure.
6. Install the outer bearing on the spindle.
7. Install the inner nut on the spindle. Tighten the inner
to 200 lbs. ft. (271 N•m) while rotating the wheel
nut
hub.
lubricant of the same
used in
Note: If the dowel
Never tighten the inner nut for alignment. This can preload
th
1 - Inner nut
2 - Dowel pin
3 - Dowel-type lock washer
4 - Outer nut
• Install the Dowel-type lock washer on the spindle.
washer, turn it over and reinstall. If required, loosen the
inner nut just enough for alignment.
e bearing and cause premature failure.
4
pin and washer are not aligned, remove
1
2
3
IMPORTANTIMPORTANT
39
Wheel Adjustment Systems
• Install the outer nut on the spindle and tighten to
350 lbs. ft. (475 N•m).
• Verify end-play, see “Verify Wheel End Play Procedure."
Three-piece Tang-type Lock Washer System
1
2
3
1 - Inner nut
2 - Tang-type lock washer .123” thick
3 - Outer nut
• Install the Tang-type lock washer on the spindle.
IMPORTANTIMPORTANT
Never tighten the inner nut for alignment. This can preload
bearing and cause premature failure.
the
Four-piece Tang/Dowel-type Lock Washer System
3
4
5
1
2
1 - Inner nut
2 - Dowel pin
3 - Dowel-type lock washer
4 - Tang-type lock washer .0478” thick
5 - Outer nut
• Install the Dowel-type lock washer on the spindle.
Note: If the dowel
pin and washer are not aligned, remove
washer, turn it over and reinstall. If required, loosen the
inner nut just enough for alignment.
• Install the outer nut on the spindle and tighten to 250
lb
s. ft. (339 N•m).
• Verify end-play, see “Verify Wheel End Play Procedure."
• After verifying end-play, secure wheel nuts by bending one of the locking washer tangs over the outer
wheel nut
and another tang over the inner wheel nut.
• Go to step 12.
IMPORTANTIMPORTANT
Never tighten the inner nut for alignment. This can preload
e bearing and cause premature failure.
th
• Install the Tang-type lock washer on the spindle.
• Install the outer nut on the spindle and tighten to 250
lbs.
ft. (339 N•m).
• Verify end-play, see “Verify Wheel End Play Procedure."
• After verifying end-play, secu
re the outer nut by
bending (180° apart) two opposing tangs of the
locking washer over the outer nut.
12. Install the following:
• New gasket at axle shaft flange.
• Axle shaft.
• Axle flange nuts and tighten to specified torque.
13. Lubricate axle wheel ends.
40
Wheel End
Wheel Adjustment
Verify Wheel End-play Procedure
Verify end-play meets specification using a dial indicator. An
indicator with .001" (.03 mm) resolution is required. Wheel
end-play is the free movement of the tire and
along the spindle axis.
Correct end-play is .001-.005” (.025-.125 mm).
1. Attach a dial indicator with its magnetic base to the
or brake drum as shown below.
hub
2. Adjust the dial indicator so that
is against the end of the spindle with its line of action
approximately parallel to the axis of the spindle.
3. Grasp the wheel assembly at the 3 o’clock and
9 o’clock positions. Push the wheel assembly in and
out while oscil
bearing end-play as the total indicator movement.
If end-play is not within specification, readjustment is
quired.
re
lating it to seat the bearings. Read
CAUTIONCAUTION
wheel assembly
its plunger or pointer
Adjust End-play with Wheel Hub
With indicator mounted at bottom, push / pull at sides of
drum.
Readjust Wheel End-play Procedure
Excessive End-play: If end-play is greater than .005"
(.127 mm), remove the outer nut and pull the lock washer
away fro
inner nut to the next alignment hole of the dowel-type washer
(if used). Reassemble the washer and retorque the outer nut.
Verify end-play with a dial indicator.
m the inner nut, but not off the spindle. Tighten the
Wheel End
Adjust End-play with Tire and Wheel Assembly
Insufficient End-play: If end-play is
outer nut and pull the lock washer away from the inner nut,
but not off the spindle. Loosen the inner nut to the next
adjustment hole of the dowel-type washer (if used). Reassemble the washer and retorque t
with a dial indicator.
Fine Tuning the End-play: If,
ment procedures, end-play is still not within the .001"-.005”
5-127 mm) range, disassemble and
(.02
nents. If parts are found to be defective, replace the defective
parts, reassemble
cedure. Verify end-play with a dial indicator.
and repeat wheel bearing adjustment pro-
not present, remove the
he outer nut. Verify end-play
after performing the readjust-
inspect the compo-
41
Lubricate Wheel End
Wheel Adjustment
IMPORTANTIMPORTANT
Before operating the axle, the wheel hub cavities and bearings must be lubricated to prevent failure.
When wheel ends are serviced, follow Spicer’s wheel
end lubrication procedure before operating the axle.
Spicer axles may be equipped with either of two (2)
wheel-end designs:
• Wheel ends with an oil fill hole.
• Wheel ends without an oil fill hole .
Wheel Ends with an Oil Fill Hole
1. Remove the oil fill plug.
2. Pour half (1/2) a pint of axle sump lubricant into
each hub through the wheel end fill hole.
3. Install oil fill plug and tighten to specified torque.
Wheel End with Oil Fill Hole
1
2
1 - Wheel end oil fill hole
2 - Proper lubricant level
Wheel End without Oil Fill Hole
1 - Lubricant flow from sump
1
42
Wheel Adjustment
Wheel Ends without Oil Fill Hole
1. With axle level and wheel ends assembled, add lubri-
cant through filler hole in carrier until
with the bottom of filler hole.
2. Raise the right side of the axle six (6) inches (152
mm
) or more. Hold axle in this position for one (1)
minute.
3. Lower the right side.
4. Raise the left side of the axle six (6) inches (152
mm
) or more. Hold axle in this position for one (1)
minute.
5. Lower the left side.
6. With axle on a level surface, add lubricant through
carrier oil filler hole
tom of the hole.
Note: Axles witho
mately 2.5 additional pints of lubricant to bring the lube
level
ut wheel end fill holes will require approxi-
even with the bottom of fill hole.
until fluid is level with the bot-
fluid is level
1 - Oil will run into wheel end
2 - Oil will run into wheel end
1
2
Wheel End
43
Lubrication
Lubrication
The ability of a drive axle to deliver quiet, trouble-free operation over a period of years is largely dependent upon the use
of good-quality gear lubrication in the correct quantity. The
most satisfactory results can be obtained by following the
directions contained in this manual.
The following lubrication instructions represent the most current recommendations from Dana.
Approved Lubricants
General - Gear lubrications acceptable under military specifi-
cation (MILSPEC) MIL-L-2105D (Lubricating Oils, Gear, Multipurpose) are approved for use in Spicer Drive Axles.
The MIL-L-2105D specification defines performance and viscosity requirements for multigrade oils. It supersedes both
MIL-L-210
MIL-L-10324A. This specification applies to both petroleumbased and synthetic based gear lubricants if they appear on
the most current “Qualified Products List
MIL-L-2105D.
Note: The use of separate oil additives and/or friction modifi-
5B, MIL-L-2105C and cold weather specification
” (QPL-2105) for
ers are not approved in Spicer Drive Axles.
Recommendations for Viscosity/Ambient Temperature
The following chart lists the various SAE Grades covered by
MIL-L-2105D and the associated ambient temperature range
from each. Those SAE grades shown with an asterisk (*) are
available in the Spicer family of synthetic gear lubricants.
The lowest ambient temperatures covered by this chart are
-40°F and -40°C. Lubrication recommendations for those
applications which consistently operate below this temperature range must be obtained through Dana by contacting
your local Dana representative.
Grade Ambient Temperature Range
75W -40°F to -15°F (-40°C to -26°C)
75W-80 -40°F to 80°F (-40°C to 21°C)
75
W-90* -40°F to 100°F (-40°C to 38°C)
140 -40°F and above (-40°C and above)
75W-
80W-90 -15°F to 100°F (-26°C to 38°C)
Synthetic Based - Synthetic-based gear lubricants exhibit
superior thermal and oxidation stability, and generally
degrade at a lower rate when compared to petroleum-based
lubricants. The performance characteristics of these lubricants include extended change intervals, improved fuel economy, better ext
cleaner component appearance. The family of Spicer gear
lubricants represents a premium quality synthetic lube
which fully meets or exceeds the requirements of
MIL-L-2105D. These products, available in both 75W-90
and 80/W-140, have demonstrated superior performance in
comparison to others qualified under the MILSPEC, as demonstrated by extensive laboratory and field testing. For a complete list of Spicer-approved
your local Dana representative. See back cover of this manual
for appropriate phone number.
Makeup Lube - Maximum amount of non-synthetic makeup
lube is 10%.
reme temperature operation, reduced wear and
synthetic lubricants, contact
80W-140* -15°F and above (-26°C and above)
85W-140 10°F and above (-12°C and above)
* Available in the Spicer family of synthetic gear lubricants.
44
Lube Change Intervals
This product combines the latest manufacturing and part
washing technology. When filled with a Spicer-approved
synthetic lubricant at the factory, the initial drain is
not required.
Change the lubricant within the first 5,000 miles of operation when not using a Spicer-approved synthetic lubricant
in either a new axle or after a carrier head replacement.
Base subsequent lubricant changes on a combination of
the following chart and user assessment of the application
and operating environment.
Lubrication
Severe Service Lubrication Change Intervals - Severe ser-
vice applications are those where the vehicle consistently
operates at or near its maximum GCW or GVW ratings, dusty
wet environments, or consistent operation on grades
or
greater than 8%. For these applications, the
WAY portion of the chart should be used. Typical applications
are construction, logging, mining and refuse removal.
Note: Clean metallic particles from the magnetic filler plug
Lubrication
ON/OFF HIGH-
and drain plugs. Clean or replace the breather yearly to
avoid lube contamination due to water ingestion.
Synthetic or
Mineral
Syntheti
Synthetic** SHAES-256 SAE 75W-90,
Mineral
Base
* Axles using LMS wheel end system
** Axles using adjustable wheel bearing system
Lubricant SAE Change Interval for Line Haul Change Interval for Voca-
c* SHAES-256 SAE 75W-90 500,000 miles [800,000 Km] or
75W-140
MIL-L-2105E/J02360,
API GL-5 Gear Oil,
L-PRF-2105E
MI
75W, 75W-90,
75W-140, 80W90, 85W-140
5 years
250,000 miles (400,000 Km) or
3 years
120,000 miles [193,000 Km] or
1 year
tional
120,000 miles (193,000 Km)
or 1year
60,000 miles [96,500 Km] or 1
year
60,000 miles [96,500 Km] or
1 year
45
Change Lube
Lubrication
Drain
1. Drain when the lube is at normal operating tempera-
ture (150°-200°F [66°-93°C]). It
minimize the time necessary to fully drain the axle,
this insures the axle is flushed.
2. Remove the bottom two carrier t
screws and allow the lube to drain into a suitable
ainer.
cont
Note: Dispose
posal methods approved for mineral- or syntheti
oils.
3. Inspect breather for clogging or corrosion. Clean or
of all used lubricants properly by following dis-
ce as necessary.
repla
will run freely and
o housing cap-
c-based
Fill
1. Reinstall bottom two carrier to housing capscrews –
use Loctite 270 and torque to 142–158 lbs. ft. (193214 N•m).
2. Remove the filler hole plug from the side of the carrier and fill the axle with the approved lubricant until
with the bottom of the hole.
level
3. If wheel ends were removed, follow instructions in
the wheel end ser
Always use the filler hole as the final reference. If lube is level
with
the bottom of the hole, the axle is properly filled.
Note: Lube fill capacities are basic guid
based on the angle the axle is installed in a particular
chassis. Torque fill plug to 40–60 lbs. ft. (54–82 N•m).
e axle can be filled through the axle housing breather
TIP: Th
hole. Fill until lube level is even with the bottom of filler hole in
side of carrier.
vicing section.
elines and will vary
46
Proper Vehicle Towing
Proper Vehicle Towing
Lift the drive wheels completely off of the ground or damage
will occur.
WARNINGWARNING
Do not lift the front wheels (non-drive wheels). This alters
oil’s position in the drive axle, draining it away from the
the
drive pinion and its bearings. If the pinion is rotated under
these conditions for any period of time, bearings will overheat resulting in axle damage or failure.
This is impossible to lift the drive wheels, remove all axle
shafts to prevent gear
vent loss of lubricant and a possible
lowing section Proper Vehicle Towing with Wheel Differential
Lock for removal procedure.
rotation and cap the wheel hubs to pre-
road hazard. See the fol-
With Truetrac Limited Slip Differential
These differentials perform like conventional (open) differentials under normal driving conditions - until traction control is
needed. Then
resistance to the wheel (or axle) with the lesser traction.
the imbalanced gear forces automatically apply
When the vehicle experiences unequal side to side traction
instance on wet, muddy, icy or sand/gravel terrain), the
(for
pinions resist rotation in the case and transfer torque from
one side gear to the other. All mating pinions tend to separate
from each other and from the side gears and they wedge into
their case pockets. This provides a friction force that retards
or prevents the wheel with lesser traction from rotating and
spinning out.
Proper Vehicle Towing
Planetary pinion gears are supported in pockets
Each pinion meshes with its side gear and with a mating pinion of the opposite planetary gear set.
of the case.
47
Torque Flow
Torque Flow
While driving with equal load on and equal traction under both
drive wheels, the T ruetrac differential provides equal torque to
each wheel.
1
1 - Torque flow distribution while operating with
equal loadin
With unequal load and/or traction on each drive
major portion of the torque will be transferred from one side
to the other to reduce the chance of a one wheel spin out.
1 - Torque flow distribution with less load over or
ground
g and ground coefficient
wheel, a
1
coefficient under left wheel
48
Torque Chart
Torque Chart
Location Thread Size Class/Grade Torque Specification
Pinion Shaft End Nut M36X1.5 10.9 625-753 lbs. ft. (847-1021 N•m)
Ring Gear to Case Capscrew
Carrier Cap Capscrew M14X2 10.9 130-150 lbs. ft. (176-203 N•m)
Head to Housing Capscrew M14X2 10.2 140-160 lbs. ft. (190-217 N•m)
ABS Set Screw .312-18 18-26 lbs. ft. (25-35 N•m)
M14X2 (S110)
M16X2 (S130)
10.9
10.9
140-160 lbs. ft. (190-217 N•m)
225 +/- 10 lbs. ft. (305 +/-13 N•m)
Torque Chart
49
For spec‘ing or service assistance, call 1-877-777-5360 or visit our website at www.dana.com
Dana Commercial Vehicle Products Group
3939 Technology Drive
Maumee, Ohio, USA 43537
www.dana.com
All applications must be approved by the Application Engineering Department. Specifications and/or design are subject to change without notice or obligation. Printed in USA AXSM-0055 04/11
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